Flooring system having large floor pattern

ABSTRACT

Laminated flooring planks include decorative motifs, mechanically embossed-in-registration surface textures, recessed perimeters, and locking mechanisms. By arranging portions of the decorative motifs along edges of a flooring plank, a periodic flooring pattern larger than an individual plank and that spans across both the length and width of a number of planks may be formed by placing identical planks adjacent to one another in a horizontal direction and adjacent in a vertical direction.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to laminated materials. More particularly, the present invention relates to a flooring system of interlocked laminated materials having decorative motifs and surface textures that are mechanically embossed in registration with their decorative motifs.

2. Discussion of the Related Art

Because of their look and feel, traditional building and finishing flooring materials such as fine woods, slate, granite, stones, brick, and concrete are generally preferred by consumers. However, such traditional building and finishing flooring materials tend to be expensive to produce and install. For example, while a solid wood floor has a highly valued luxurious appearance, the materials and labor required to install such floors can be prohibitively expensive.

Many alternatives to traditional building and finishing flooring materials are available, including laminates such as high-pressure laminates (HPL), direct-pressure laminates (DPL), and continuous-pressure laminates (CPL). However, such alternatives typically do not possess the realistic look and texture of the traditional building and finishing flooring materials. For example, most alternatives having an outer surface with a wood motif look fake and can readily be identified as something other than authentic wood. Furthermore, while high quality HPL, DPL, or CPL boards may visually look like wood, their textures readily reveal that they are not.

One problem with most alternatives to traditional building and finishing flooring materials is that their surface textures do not match their decorative motifs. For example, visual depictions of wood knots in alternative flooring materials are not matched with surface textures characteristic of the wood knots. Accordingly, the attractiveness of these alternative materials is significantly reduced.

One approach used to match the surface texture of alternative flooring materials to their decorative motifs includes a technique known as chemical embossing. In chemical embossing, the surface texture of the alternative material is developed by chemically reacting an ink that forms the decorative motif with an agent added to a sub-surface layer. While somewhat successful, the resulting surface texture tends to lack the textual sharpness and three-dimensional characteristics of traditional materials.

As an alternative to the traditional building and finishing flooring materials laminated materials may be mechanically embossed to produce a surface texture. See, for example U.S. patent application Ser. No. 09/903,807 and U.S. Pat. No. 6,401,415, which are hereby incorporated by reference. Such methods produce embossed-in-registration laminated materials having decorative motifs and matching high-quality three-dimensional textures. Embossed-in-registration laminated materials require accurate registration of mechanical embossment and the decorative motif. An advantage of embossed-in-registration laminated materials is that they can realistically reproduce the look and feel of traditional products.

No matter what type of flooring system is used, the flooring system must be easily moved to a work site while being easy and quick to install. To this end, assembly and locking mechanisms may be incorporated within flooring systems to facilitate on-site installation. One type of assembly and locking mechanism is the tongue and groove system used for connecting panels. It is understood that such tongue and groove systems are disclosed in Cherry, U.S. Pat. No. 2,057,135, and in Urbain, U.S. Pat. No. 2,046,593. For example, FIG. 1 can be interpreted to illustrate a tongue and groove system 11 that uses clips 12 to secure panels together.

Another type of assembly and locking mechanism is understood to be disclosed in Chevaux, U.S. Pat. No. 3,946,529 where a flooring system 13 appears to be connected using a tongue and groove system arranged underneath the flooring, reference FIG. 2.

Still another assembly and locking mechanism is taught in Kajiwara, U.S. Pat. No. 5,295,341. There, it is understood that laminated boards are provided with a snap-together system such as a groove-tongue joint. As a result the laminated boards can be assembled without glue. Referring to FIG. 3, the laminated boards are provided with a locking means in the form of a groove connector 16, and a tongue connector 18. The groove connector 16 has forwardly protruding grooves 20, while the tongue 18 is provided with a pair of forwardly diverging sidewalls 22 and 24 that are separated by an elongated groove 26. The sidewalls include rear locking surfaces 28 and 36. The sidewalls can be compressed together to enable locking.

Another type of assembly and locking mechanism is the snap-together joint is suggested in Märtensson, U.S. Pat. No. 6,101,778. As shown in FIG. 4, it is understood that laminated boards are provided with a locking means comprised of a groove 6 and a tongue 7 that form a tongue-groove assembly. The groove 6 and tongue 7 may be made of water tight material and snapped together with a portion 9 fitting in a slot 4.

While the aforementioned assembly and locking mechanisms have proven useful, they have not been used with embossed-in-registration laminate systems in which embossed-in-registration decorative motifs or graphics align across joints between the individual embossed-in-registration laminates. This significantly detracts from the visual and textural impression of systems comprised of embossed-in-registration laminate boards. Therefore, a new embossed-in-registration laminate system in which the visual and textural patterns cross joints while retaining the embossed-in-registration aspects would be beneficial. Even more beneficial would be an embossed-in-registration laminate system comprised of interlocking embossed-in-registration laminate boards in which the visual and textural patterns cross joints while retaining embossed-in-registration aspects.

Further, the aforementioned flooring systems have a relatively low ability to resist wear. While not wishing to be bound by any particular theory, it is hypothesized that premature aging (wear) begins at or near the perimeter edges and/or along tongue and groove lines. The aforementioned flooring systems have a substantially even (level) surface texture such that the center and perimeter of each panel contact users (e.g., pedestrians) an equal amount. The perimeter of each panel, however, is substantially weaker than the center of the panel and therefore deteriorates first.

In addition, flooring systems typically do not have decorative motifs or pattern designs that are longer than the length of a plank. For example, in a flooring system designed to reproduce a wood floor having wood strips, the length of the wood strip pattern is typically equal to or shorter than the length of a single plank. This is desirable in related art flooring systems because it does not require the installer to plan more than one plank beyond the plank being installed.

Accordingly, there is a need for a workable method of fabricating alternative building or finishing materials where the alternatives have the realistic look and feel of traditional products and have an increased capacity to resist premature wear, and in which the minimum number of planks is used maintained while still being able to create design motifs or pattern elements with a length greater than that of a single plank.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to embossed-in-registration flooring system that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.

An advantage of the present invention provides an embossed-in-registration flooring system including individual adjacent flooring planks having embossed-in-registration decorative motifs where at least one of a surface texture and decorative motif is substantially aligned between adjacent flooring plank.

Another advantage of the present invention provides an embossed-in-registration flooring system including interlocked flooring planks having embossed-in-registration decorative motifs where at least one of a surface texture and decorative motif is substantially aligned between adjacent flooring planks such that substantially continuous embossed-in-registration patterns are formed across the interlocked flooring planks.

Another advantage of the present invention provides an embossed-in-registration flooring system may, for example, include flooring planks wherein a surface of a perimeter of each individual flooring plank may be recessed such that an upper surface of the perimeter of the flooring planks is below a portion of an upper surface of the flooring planks surrounded by the perimeter.

Another advantage of the present invention provides a plank comprising a plurality of sides defining a perimeter; a plurality of edge patterns arranged proximate at least one first portion of the perimeter, wherein at least two of the plurality of edge patterns are substantially identical; and at least one bulk pattern arranged adjacent the plurality of edge patterns and proximate at least one second portion of the perimeter, wherein at least one bulk pattern and an edge pattern adjacent the at least one bulk pattern forms a substantially continuous pattern.

Another advantage of the present invention provides a flooring system, comprising at least two planks adjacent each other along a predetermined direction, wherein each plank comprises: a plurality of sides defining a perimeter; a plurality of edge patterns arranged proximate at least one first portion of the perimeter, wherein at least two of the plurality of edge patterns are substantially identical; and at least one bulk pattern arranged adjacent the plurality of edge patterns and proximate at least one second portion of the perimeter, wherein at least one bulk pattern and an edge pattern adjacent the at one least bulk pattern forms substantially continuous pattern; herein edge patterns of the at least two planks form a substantially continuous pattern.

A further advantage of the present invention provides a floor panel, comprising a plurality of sides defining a perimeter; a surface having thereon a decorative motif, said decorative motif comprising at least two edge patterns adjacent each of the sides of the panel and at least one bulk pattern in the interior of the panel and adjacent the edge pattern on each side, wherein at least one edge pattern along a side is substantially identical to the edge pattern in a corresponding position along an opposite side; and wherein at least one portion of the decorative motif along a side is substantially different from the corresponding portion of the decorative motif along an opposite side.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. These and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.

In the drawings:

FIG. 1 illustrates a related art assembly and locking mechanism;

FIG. 2 illustrates another related art assembly and locking mechanism;

FIG. 3 illustrates yet another related art assembly and locking mechanism;

FIG. 4 illustrates still another related art assembly and locking mechanism;

FIG. 5 illustrates a perspective view of components in an embossed-in-registration flooring plank according to the principles of the present invention;

FIG. 6 illustrates a press machine capable of fabricating embossed-in-registration flooring planks in accordance with the principles of the present invention;

FIG. 7 illustrates an embossed-in-registration flooring plank in one aspect of the present invention;

FIG. 8 illustrates a top view of a system of embossed-in-registration flooring planks in another aspect of the present invention;

FIG. 9 illustrates a cross-sectional view along line 9-9 shown in FIG. 8;

FIG. 10 illustrates a top view of a system of embossed-in-registration flooring planks in yet another aspect of the present invention;

FIG. 11 illustrates a cross-sectional view along line 11-11 shown in FIG. 10;

FIGS. 12A and 12B illustrate schematic views including a perimeter surface portion of a flooring plank in accordance with the principles of the present invention;

FIGS. 13A and 13B illustrate a flooring system in still another aspect of the present invention;

FIGS. 14A-14C illustrate an exemplary plank of a flooring system in still another aspect of the present invention and

FIGS. 15A-15E illustrate an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention.

FIG. 16 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention;

FIG. 17 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention;

FIG. 18 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention;

FIG. 19 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention;

FIG. 20 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention;

FIG. 21 illustrates an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention; and

FIGS. 22A-22D illustrate an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention.

FIG. 23 illustrate an exemplary method of forming patterns on a flooring plank in accordance with the principles of the present invention.

FIG. 24 illustrate an exemplary method of forming patterns of a first size on a flooring plank in accordance with the principles of the present invention.

FIG. 25 illustrate an exemplary method of forming patterns of a second size on a flooring plank in accordance with the principles of the present invention.

FIG. 26 illustrate an exemplary method of forming patterns of a third size on a flooring plank in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

FIG. 5 generally illustrates components of a flooring plank according to the principles of the present invention.

Referring to FIG. 5, an embossed-in-registration flooring system may, for example, include at least one flooring plank. In one aspect of the present invention each flooring plank may include a board substrate 40 made out of a substrate material (e.g., a medium or high density fiberboard, chipboard, etc.), at least one base sheet 48 (e.g., a kraft paper sheet) impregnated with predetermined resins and arranged over and/or under the board substrate 40, a decorative paper sheet 44 about 0.15 mm thick and impregnated with a polymerizable resin (e.g., phenols such as melamine) arranged over the board substrate, and at least one protective overlay sheet 46 arranged over the decorative paper sheet 44. In one aspect of the present invention, each protective overlay sheet 46 may be formed from a highly resistant paper impregnated with a melamine solution containing corundum (Al₂O₃), silica, etc. In another aspect of the present invention, different papers may be arranged between the decorative paper sheet 44 and the board substrate 40. In one aspect of the present invention, the at least one protective overlay sheet 46 and the base sheet 48 may be impregnated with a resin. In another aspect of the present invention the resin impregnating the at least one protective overlay sheet 46 and the base sheet 48 may be different from the melamine resin used to impregnate the decorative paper sheet 44.

In one aspect of the present invention, flooring planks within a flooring system may be fabricated from substantially the same paper, resin, etc. For example, flooring planks within a flooring system may be fabricated using paper made from substantially the same paper fibers (having, for example, substantially the same ash content, color, and orientation) on the same on the same paper making machine. Further, flooring planks within a flooring system may be fabricated using paper originating from a single, contiguous section on the manufacturing spool. All of the aforementioned paper use restrictions that may be employed in fabricating flooring planks of a flooring system ensure that impregnated papers will always have substantially the same final dimensions after they are pressed and cured. In one aspect of the present invention, the warehousing of paper used to fabricated flooring planks within a flooring system may be controlled such that the time, temperature, and humidity in which the paper is stored is maintained to facilitate consistent flooring plank dimensions. In another aspect of the present invention, flooring planks within a flooring system may be fabricated using cellulose paste made from the same manufacturer. In yet another aspect of the present invention, flooring planks within a flooring system may be fabricated using resins made from the same manufacturer. In still another aspect of the present invention, the resins may contain powder originating from substantially the same source, have substantially the same chemical and physical qualities, and be mixed in the same reactor. Further, flooring planks within a flooring system may be fabricated using resins have a substantially constant solids content. All of the aforementioned resin use restrictions that may be employed in fabricating the flooring planks ensure that impregnated papers will always have substantially the same final dimensions after they are pressed and cured. In still another aspect of the present invention, each of the flooring planks within a flooring system may be fabricated using substantially the same impregnation process. For example, when dipping the various sheets of paper into melamine resin, the paper should experience a constant, uniform melamine load. Further, a band tension and oscillation of the impregnation machine should be precisely controlled as they influence the degree to which the various paper sheets are impregnated with the resin.

According to the principles of the present invention, the aforementioned sheets and substrates may be fabricated into an embossed-in-registration flooring system including a plurality of interlocking flooring planks. To produce such a flooring system, a press machine, such as a press machine shown in FIG. 6, may be used to mechanically emboss each flooring plank in registration with a decorative motif arranged on the decorative paper sheet 44.

Referring to FIG. 6, the press machine may, for example, include a base 42, a top press 54, and an upper press plate 56. In one aspect of the present invention, the upper press plate may include an embossing pattern (e.g., a three-dimensionally textured surface). Accordingly, the embossing pattern may, for example, include elevated ridges, dots, depressions, etc., of any design capable of being aligned with a decorative motif formed on the decorative paper sheet 44.

According to the principles of the present invention, the impregnated decorative paper sheet 44 arranged on the board substrate 40 must be accurately positioned relative to the embossing pattern of the upper press plate to enable an embossed-in-registration flooring plank. In one aspect of the present invention, alignment between the embossing pattern of the press plate and the decorative motif must be ensured when the press is in a locked position and the board is under pressure. The degree of control required may vary depending on the type of decorative motif used. For example, alignment of a wood grain embossed-in-registration motif across adjacent embossed-in-registration flooring planks requires a higher degree of alignment than alignment of a wood grain embossed-in-registration motif that is not aligned with adjacent flooring planks.

Alignment between the decorative motif on the decorative paper sheet 44 and the embossing pattern on the upper press plate 56 may be achieved by removing about 2 to 3 millimeters of material around the perimeter of the board substrate 40 in a milling process thereby yielding several reference planes (e.g., board edges) and a board substrate having tightly controlled dimensions. Next, an impregnated decorative paper sheet 44 having exterior dimensions about 8 or 10 mm smaller than the board substrate 40 is arranged on the board substrate 40. In one aspect of the present invention, the impregnated decorative paper sheet 44 may be arranged on the board substrate 40 using the board edges as alignment means. In one aspect of the present invention, alignment marks may be arranged on the board substrate 40 and be alignable with alignment marks provided on the decorative paper sheet 44.

In one aspect of the present invention, the decorative paper sheet 44 may be attached to the board substrate 40 via static electricity. After they are attached, the decorative paper sheet 44 and the board substrate 40 are arranged on a carriage feeding into the press machine. The static electricity may substantially prevent the decorative paper sheet 44 from being accidentally displaced as the board substrate 40 is moved with the carriage. In one aspect of the present invention, the carriage may be stopped just before it enters into the press machine such that the decorative paper sheet 44 may be precisely arranged over the board substrate 40 using, for example, tweezers (not shown). In another aspect of the present invention, the tweezers may be used to precisely arrange the decorative paper sheet 44 over the board substrate 40 arranged on the lower press plate. In one aspect of the present invention, the decorative paper sheet 44, the at least one protective overlay sheet 46, and the optional base sheet 48 may be arranged over the board substrate 40 prior to being arranged within the press machine. After the decorative paper sheet 44 is arranged over the board substrate 40, the carriage may be moved out of the press machine. Next, an alignment system substantially aligns the decorative paper sheet 44/board substrate 40 system with the embossing pattern in the upper press plate 56. In one aspect of the present invention, the alignment system may use the board edges to substantially align the decorative motif 44 with the embossing pattern on the upper press plate 56. The press machine may be operated after the alignment is complete.

In one aspect of the present invention, after the components illustrated in FIG. 5 are arranged within the press machine and aligned with the embossing pattern, the various sheets and substrate may be pressed and cured for predetermined amount of time until the resins set, yielding an extremely hard and wear resistant flooring plank. For example, after being inserted into the press machine and aligned with the embossing pattern, the board substrate 40, decorative paper sheet 44, protective overlay sheet 46, and optional base sheet 48 may be heated at a temperature of about 160-220° C. and pressed together under a pressure of about 20-40 Kg/cm² for about 20 to 60 seconds. Accordingly, the top press 54 presses the embossing pattern of the upper press plate 56 into the decorative paper sheet 44 and board substrate 40 structure. The combination of the applied heat and pressure fuses the decorative paper sheet 44 and the board substrate 40 together. The alignment system ensures that the decorative paper sheet 44 is substantially aligned with the embossing pattern in the upper press plate 56. Accordingly, melamine resin within the various sheets may be cured and an embossed-in-registration plank may be produced.

In one aspect of the present invention, porosity within the fused piece may be minimized by slowly curing the resins (e.g., the melamine). Accordingly, as the operating temperature is reduced, the time during which the various sheets within the press machine are pressed is increased. In another aspect of the present invention, as the press plate 56 is heated to about 160-220° C. the embossing pattern included within the press plate may expand. Accordingly, the embossing pattern on the press plate 56 may be provided so as to compensate for the expansion of the pattern. Therefore, the dimensions of the embossing pattern are provided such that they substantially correspond to the design of the decorative motif when the resins within the components of FIG. 5 are cured.

According to the principles of the present invention, a mechanically embossed surface texture may be imparted to an individual flooring plank having a decorative motif. In one aspect of the present invention, the mechanically embossed surface texture may be provided in registration with the decorative motif. Accordingly, an embossed-in-registration flooring plank may be fabricated. In another aspect of the present invention, a plurality of embossed-in-registration flooring planks may be joined together to form an embossed-in-registration flooring system. In yet another aspect of the present invention, at least a portion of embossed-in-registration patterns of adjacent flooring planks may be substantially aligned with each other to form substantially contiguous embossed-in-registration patterns across adjacent flooring planks within the flooring system.

While the embossed-in-registration process described above is suitable for embossed surface textures that are less than about 0.2 mm deep, deeper surface textures may be problematic. Embossing patterns capable of imparting deep surface textures, for example, require relatively large press plate protrusions that tend to disturb the pressure homogeneity applied across the board surface. This pressure disturbance can cause distortions in the final product. In one aspect of the present invention, embossed surface textures may be formed greater than about 0.2 mm deep by hollowing out the board substrate 40 at locations where deep surface textures are desired. In one aspect of the present invention, the hollowing out process may be performed before, during, or after the perimeter of the board substrate 40 is milled as described above. In another aspect of the present invention, the board edges may be used to locate the boundaries of the hollowed out portions of the board substrate 40.

Referring to FIG. 7, an embossed-in-registration flooring plank 60, fabricated according to the process described above may optionally include a protective padding layer 50 on one side. The mechanically embossed surface texture is registered with the decorative motif 68 of the decorative paper sheet 44. By registration, it is meant that the embossed surface texture is substantially aligned with the decorative motif of the decorative paper sheet 44. By providing an embossed-in-registration flooring plank, a realistic representation of a natural material may provided to individual flooring planks. While the decorative motif illustrated in FIG. 7 realistically represents the image and texture of a wood grain, it should be appreciated that other embossed-in-registration designs such as ceramic planks, concrete, marble, etc., may be produced.

According to the principles of the present invention, each of the individual flooring planks may, for example, include at least one locking mechanism.

In one aspect of the present invention, locking mechanisms may be incorporated within the board substrate 40 before the embossing pattern is imparted to the surface of the board substrate 40 in registration with the decorative motif. Accordingly, locking mechanisms may be fabricated within individual board substrates 40. Next, the locking mechanisms may be used to join individual board substrates together to form a plank structure. The plank structure may then be inserted into the press 54. After the embossing pattern is imparted to the plank structure and the fused components are fused together, the plank structure is removed from the press 54. Next, embossed-in-registration flooring planks 60 within the fused plank structure are separated by unlocking the locking mechanisms. In one aspect of the present invention, cutting tools may be used to assist in the separation and to ensure the decorative motif is not damaged.

In another aspect of the present invention, the locking mechanisms may be incorporated within the board substrate 40 after the embossing pattern is imparted to the surface of the board substrate 40 in registration with the decorative motif. Accordingly, a board substrate 40 having relatively large dimensions of, for example, 4′×8′, may be embossed by the press 54. Next, the resulting embossed-in-registration substrate may be cut into a plurality of individual embossed-in-registration flooring planks 60. In one aspect of the present invention, edges of the individual embossed-in-registration flooring planks 60 may have smooth edges and precise dimensions. In one aspect of the present invention, the cutting may be performed using shaping tools, milling tools, cutting tools, breaking tools, etc. In one aspect of the present invention, the board substrate may be cut by the press machine. Accordingly, the board substrate 40 may be cut into units (e.g., strips) having dimensions of, for example, 300×300 mm, 400×400 mm, 600×600 mm, 1,200×300 mm, 1,200×400 mm, etc. Next, the locking mechanisms may be incorporated within the individual embossed-in-registration flooring planks 60. In one aspect of the present invention, the locking mechanisms may be hidden beneath the surface of the flooring planks or they may be visible.

According to the principles of the present invention, the locking mechanisms may be incorporated within the individual embossed-in-registration flooring planks 60 by aligning the at least one of the board edges, alignment marks, decorative motifs, and surface textures of the flooring plank with a milling tool. By aligning the milling tool with any of the aforementioned alignable features, locking mechanisms may be milled into the sides of the board substrates 40 such that, when flooring planks 60 are joined together the at least a portion of the decorative motifs form a continuous pattern and at least a portion of the embossed-in-registration patterns form a substantially continuous surface texture across adjacent flooring planks.

According to the principles of the present invention, the embossed-in-registration flooring plank 60 may include a locking mechanism 64 (e.g., at least one of a tongue and groove locking system, a snap-together locking system, etc.) extending along all four sides of the embossed-in-registration laminate 60. For example, a snap-together locking system may be added to all four sides of the embossed-in-registration flooring plank 60 and used to connect multiple embossed-in-registration flooring planks 60 into an embossed-in-registration flooring system 300 (as shown in FIG. 8). The number and location of locking mechanisms may depend on the desired configuration of the embossed-in-registration flooring system. For example, when an embossed-in-registration flooring system abuts a corner, only two locking mechanisms are required (along the sides).

Referring to FIG. 8, the embossed-in-registration flooring planks A and B may, for example, include locking mechanisms along four sides (e.g., along joints J1, J2, J3, and J4). Embossed-in-registration flooring planks C and D may, for example, include locking mechanisms along four sides (e.g., along joints J1, J2, J3, and another joint not shown).

Embossed-in-registration flooring planks including the aforementioned locking mechanisms may be securely attached together with or without glue to form an embossed-in-registration laminate system 300. Multiple embossed-in-registration flooring planks may be joined together to obtain any desired shape for flooring, planking, or the like. The embossed-in-registration flooring planks may be joined to each other such that at least portions of embossed-in-registration patterns of adjacent flooring planks are substantially aligned with each other and form a substantially continuous image and embossed surface texture across flooring planks within a flooring system.

FIGS. 8 and 9 illustrate an exemplary embossed-in-registration flooring system 300 incorporating one type of locking mechanism on each of the individual embossed-in-registration flooring planks 60. FIG. 9 illustrates an exemplary embossed-in-registration flooring system including flooring planks incorporating a snap-type tongue and groove locking mechanism. In one aspect of the present invention, the snap-type tongue and groove locking mechanism may be integrated into the sidewalls of each embossed-in-registration laminate 60 so as to ensure that embossed-in-registration patterns of adjacent flooring planks are substantially aligned with each other and substantially continuous within the flooring system.

FIG. 9 illustrates a cross sectional view of FIG. 8 taken along line 9-9. As shown, the locking mechanism may be fabricated by forming a groove 230, a tongue 200, a channel 210, and a lip 220 along the edges of the embossed-in-registration flooring planks 60. The locking mechanisms on the embossed-in-registration flooring planks 60 may be joined together by inserting the tongue 200 into the groove 230 of an adjacent embossed-in-registration flooring plank 60. Subsequently, the lip 220 is secured within channel 210, thereby joining adjacent embossed-in-registration flooring planks 60 into an embossed-in-registration flooring system 300. In one aspect of the present invention, the embossed-in-registration flooring planks 60 labeled A, B, C and D may be joined together with or without glue. It should is appreciated that other types of locking mechanisms may be incorporated within the sides of the individual embossed-in-registration flooring planks 60.

Referring back to FIG. 8, each of the embossed-in-registration flooring planks 60 may, for example, exhibit an embossed-in-registration ceramic plank motif G1. The ceramic plank motif may comprise a plurality of planks in the shape of squares, rectangles, triangles, circles, ovals, any other shape or design that are separated by grout lines. In one aspect of the present invention, widths of grout lines Wh, Wv, and the intraboard grout width W may be substantially equal. When incorporating the snap-type tongue and groove locking mechanism into the embossed-in-registration flooring planks 60 the grout width adjacent the joints J1, J2, J3, and J4 on each embossed-in-registration laminate A, B, C, and D are approximately one-half the intraboard grout width W. For example, the vertical plank grout width (Wv) across joint J1 is made up of grout lines on embossed-in-registration laminates A, B, C and D, such that when the embossed-in-registration laminates A, B, C, and D are joined at J1 the vertical grout width (Wv) is approximately equal to (W). Accordingly, the grout width on any individual embossed-in-registration flooring plank 60 adjacent a joint is one-half of intraboard grout width (W). In another aspect of the present invention, the horizontal and vertical grout widths Wh and Wv may be controlled such they are substantially equal to the dimensions of the intraboard grout width W. It should be appreciated, however, that the dimensions of the grout widths in the embossed-in-registration flooring planks depend on the type of locking mechanism incorporated and the decorative motif exhibited.

In addition to grout lines, many other decorative motifs may be used in the embossed-in-registration flooring system of the present invention. Referring to FIGS. 10 and 11, a decorative motif exhibiting, for example, a wood grain surface G2 substantially aligned across joints J5 and J6 of adjacent flooring planks may be provided. According to the principles of the present invention, wood grain patterns generally include more elements (e.g., wood grain lines, wood knot 423, etc.) that extend to the perimeters of the flooring planks that need to be aligned than ceramic plank motifs. Accordingly, aligning the wood grain motif is generally more difficult than aligning grout line portions of the ceramic plank motifs. For example, aligning a first portion of a wood knot 423 on embossed-in-registration flooring plank E with a second portion of the wood knot 423 on embossed-in-registration flooring plank F is generally more complex than aligning grout line widths across joints of adjacent flooring planks. Accordingly, when fabricating a locking mechanism, consideration of all the graphic elements (e.g., wood grains lines and wood knots 423) must be considered to ensure a realistic embossed-in-registration flooring system 400. In one aspect of the present invention, at least one portion of the decorative motif may be used as an alignment marks ensuring consistent alignment of adjacent flooring planks.

In another aspect of the present invention, individual flooring planks within the embossed-in-registration flooring system 400 may be joined together with a snap-type mechanical system as illustrated in FIG. 11 depicting a cross sectional view of FIG. 10 along line 11-11. Again, alignment techniques used in the fabrication of the locking mechanism such that the embossed-in-registration laminate system 400 has a surface texture surface 423 that is substantially continuous across joints, J5 and J6. Optionally, the embossed-in-registration laminates 60 have a protective padding layer 70 under the base sheet 48.

FIGS. 12A and 12B illustrate schematic views of a flooring plank in accordance with the principles of the present invention.

Referring to FIGS. 12A and 12B, an upper surface at the perimeter, P, of each embossed-in-registration flooring plank may be recessed below an upper surface at the portions of the flooring plank surrounded by the perimeter. An object O (e.g., a users shoe, a wheel, etc.) contacting the major surface, Ms, of a flooring plank does not generally contact the surface of the perimeter, Ps, due to the perimeter's recessed surface. In one aspect of the present invention, the perimeter may include a portion of the flooring plank extending from the edge of the flooring plank approximately 3.175 mm toward the center of the flooring plank. In another aspect of the present invention, the depth to which the surface of the perimeter of the flooring plank is recessed is approximately 0.794 mm. In another aspect of the present invention, the surface of at least one portion of the perimeter of a flooring plank may not be recessed, as will be discussed in greater detail below with reference to FIG. 13.

Accordingly, the embossed-in-registration pattern may be provided to the edges of the flooring plank and may be aligned with embossed-in-registration patterns formed on adjacent flooring planks while the edges of each individual flooring plank may be prevented from prematurely wearing.

Although it has been shown in FIGS. 8 and 10 that individual flooring planks within a flooring system are substantially the same size and shape and are joined to each other such that each side of each flooring plank is joined to only one adjacent flooring plank, it should be appreciated that individual flooring planks within a flooring system may vary in size (e.g., width and/or length) and shape (e.g., rectangular, square, triangular, hexagonal, etc.). In one aspect of the present invention, individual flooring planks may have complementary shapes capable of being assembled similar to a puzzle or mosaic. Further, one aspect of the present invention contemplates that sides of individual flooring planks may contact more than one adjacent flooring plank.

In accordance with the principles of the present invention, flooring planks within a flooring system may be arranged such that at least one side of each plank includes at least one sub-panel adjacent at least two other sub-panels. In another aspect of the present invention, each plank may include, either entirely or partially, at least one sub-panel, as will be described in greater detail below.

In FIG. 13A, for example, partial sub-panel 134A of plank 130A may be a complementary sub-panel with respect to neighboring partial sub-panel 136B of plank 130B, adjacent plank 130A. With this arrangement, the partial sub-panels 134A and 136B may be made to appear as one unitary sub-panel.

Still referring to FIG. 13A, each of the planks 130A-F may comprise at least three sub-panels wherein at least one of the sub-panels is a unitary sub-panel and at least two of the sub-panels are partial sub-panels. For example, 132A is a unitary sub-panel and 134A and 136A are partial sub-panels.

In one aspect of the present invention, the unitary sub-panel 132A may provide a complete decorative motif with or without an embossed surface texture that may or may not be in registration with the decorative motif. In another aspect of the present invention, the partial sub-panels 134A and 136A of a plank may provide separated, incomplete decorative motifs with or without embossed surface textures that may or may not be in registration with the decorative motifs. In one aspect of the present invention, neighboring partial sub-panels of adjacent planks may be complementary to each other such that they provide a substantially complete decorative motif and/or surface texture and appear as a substantially continuous, unitary sub-panel. In one aspect of the present invention, complementary partial sub-panels may have complementary decorative motifs and/or embossed surface textures. Accordingly, when complementary partial sub-panels of adjacent planks are properly aligned, a substantially continuous (i.e., complete) decorative motif and/or embossed surface texture may be formed across neighboring complementary partial sub-panels. In one aspect of the present invention, sub-panels within a plank may or may not comprise substantially the same decorative motif and/or embossed surface texture.

FIG. 13B illustrates a schematic view of an exemplary plank 130 such as that shown in FIG. 13A.

In one aspect of the present invention, portions of the perimeter surface of each plank may be recessed at locations where neighboring sub-panels are not complementary. In another aspect of the present invention, portions of the perimeter surface of each plank may be non-recessed at locations where neighboring sub-panels are complementary. Referring to FIG. 13B, portions of the upper surface of the perimeter “P” of each of the planks 130 indicated by reference numeral 138 a may be slightly recessed compared to the major surface of each of the planks (see also FIG. 12B) to prevent premature wear of each of the planks. Further, portions of the upper surface of the perimeter of each of the planks 130 indicated by reference numeral 138 b may be non-recessed and substantially coplanar with the major surface of the sub-panels. Recessing only portions of the perimeter surface of each of the planks at positions not occupied by the decorative motifs and/or embossed surface textures of partial sub-panels of a plank allows complementary partial sub-panels to appear as a part of a unitary sub-panel while not significantly detracting from the overall durability of each of the planks. In yet another aspect of the present invention, portions of the surface of each plank may be recessed at locations where sub-panels of a plank are adjacent one another. Referring to FIG. 13B, portions of the upper surface of each of the planks 130 indicated by reference numeral 138 c may be slightly recessed compared to the major surface of each of the planks (see also FIG. 12B) to provide a visual and textural effect that each of the sub-panels of the plank are not a part of the same plank.

FIGS. 14A-14C illustrate an exemplary plank of a flooring system in still another aspect of the present invention.

Referring to FIGS. 14A-14C, similar to the plank shown in FIGS. 13A and 13B, portions of the upper surface of the perimeter “P” of each of the planks 130 indicated by reference numeral 138 a may be beveled to prevent premature wear of each of the planks. Further, portions upper surface of the perimeter of each of the planks 130 indicated by reference numeral 138 b may not be beveled such that they are substantially coplanar with the major surface of the sub-panels. Beveling the perimeter surface of each of the planks at positions corresponding to the decorative motifs and/or embossed surface textures of partial sub-panels of a plank allows complementary partial sub-panels to appear as a part of a unitary sub-panel while not significantly detracting from the overall durability of each of the planks. In yet another aspect of the present invention, portions of the surface of each plank may be provided with a groove at locations where sub-panels of a plank are adjacent to one another.

FIGS. 14B and 14C illustrate cross-sectional views of plank 130 taken across lines I-I′ and II-II′, respectively. Referring to FIGS. 14B and 14C, portions of the upper surface of each of the planks 130 indicated by reference numeral 138 c may be beveled to form a groove. This groove may also prevent premature wear of each of the planks. Thus, the groove provides a visual and textural effect that sub-panels of a plank are separate. In one aspect of the present invention, the bevel at 138 c may produce a groove having a substantially V-shaped groove. It is appreciated, however, that the bevel may produce other groove topographies (e.g., U-shaped grooves, etc.). In one aspect of the present invention, the beveling of each of the planks 130 at perimeter surface portion 138 a creates a groove between adjacent planks. Accordingly, the groove formed between adjacent ones of the planks, via beveling at 138 a, has substantially the same width and topography as grooves formed within the planks, via beveling at 138 c.

The motif and/or surface texture present at the recessed surface of the perimeter of each plank may or may not correspond to the motif/surface texture present at the main surface of a corresponding plank. Thus, a substantially continuous motif and/or surface texture may or may not be present across the surfaces of the perimeter and the interior of any individual plank. Alignment marks or markings (not shown) can be used to self-align a decorative motif on the planks. In one aspect of the present invention, the embossed in-registration pattern may be a free form or custom design. It is to be understood that substantially any embossed-in-registration pattern and any decorative motif may be realized by applying the principles of the present invention. In one aspect of the present invention, alignment of the planks may be done visually upon joining them together. Accordingly, alignment of the planks 130 may be performed using the decorative motif and/or embossed surface texture of each of the planks.

While it has been illustrated that the planks in FIGS. 13A, 13B, and 14A-14C are substantially rectangular, the principles of the present invention allow the planks within the flooring system to have other shapes and sizes (e.g., geometric, freeform, etc.) or different or similar dimensions such that the flooring planks may be assembled in a “mosaic”-type arrangement or other regular, semi-repetitious, or random arrangement of panels. Further, while it is illustrated that each plank comprises an identical sub-panel layout, the principles of the present invention allow the planks within the flooring system to have other sub-panel layouts (e.g., other sub-panel shapes, sizes, etc.) The individual planks within the flooring system may be cut from a board such that joints between the flooring panels of the flooring system are not visible. Further, the planks within the flooring system illustrated in FIGS. 13 and 14 may be joined together with or without glue. Still further, while it has been discussed that the embossed surface texture is substantially aligned with an underlying decorative motif, it is to be understood that substantially any embossed surface texture may be imparted to the planks of the present invention, regardless of the underlying decorative motif. Still further, the decorative motifs and/or the embossed surface texture of one plank may not be aligned or even be remotely similar in appearance and/or texture to decorative motifs and/or embossed surface textures of adjacent planks.

According to the principles of the present invention, any of the aforementioned decorative motifs and/or embossed surface textures that may or may not be embossed in registration with the decorative motifs (collectively referred to herein as “patterns”) may be applied to any of the aforementioned planks to form a substantially continuous pattern across adjacent planks arranged along a predetermined direction by forming each of the plank patterns using at least one bulk pattern and at least one edge pattern.

In one aspect of the present invention, each edge pattern may be present at a perimeter portion of the plank extending along at least a portion of at least one edge of each plank. In another aspect of the present invention, each edge pattern may extend to a predetermined distance (e.g., about one millimeter, about one inch, etc.) into the interior of the plank, away from the perimeter of the plank. In another aspect of the present invention, at least one bulk pattern may be arranged adjacent at least one edge pattern, wherein a pattern present at the edge of the bulk pattern adjacent the edge pattern may form a substantially continuous visual/textural pattern with a pattern present at the edge of the edge pattern adjacent the bulk pattern.

In one aspect of the present invention, patterns of individual planks, arranged adjacent each other along a predetermined direction within a flooring system, may complement patterns of adjacent planks (i.e., form substantially continuous patterns across adjacent planks) when edge patterns of the adjacent planks form a substantially continuous pattern. Where the flooring system described above comprises a plurality of adjacent planks arranged along the predetermined direction, and where the edges of each plank are arranged adjacent to edge patterns of other planks along the predetermined direction, edge patterns of adjacent planks are identical or substantially identical. The identical or substantially identical edge patterns of adjacent planks enable a continuous pattern to be formed across the adjacent planks.

For example, referring to FIG. 15A, an exemplary plank pattern of plank 150 may comprise two edge patterns 152 substantially identical to each other and a bulk pattern 154. As shown in FIG. 15A, the two substantially identical edge patterns 152 are present at a perimeter portion of the plank 150, extend along a portion of the opposite edges of the plank, and extend a predetermined distance into the interior of the plank 150. Still referring to FIG. 15A, the pattern present at the edge of the bulk pattern 154 adjacent the edge patterns 152 forms a substantially continuous pattern with the pattern present at the edge patterns 152 adjacent the bulk pattern.

Referring now to FIG. 15B, a plurality of planks 150A, 150B, 150C, etc., such as those illustrated in FIG. 15A may be arranged adjacent each other within a flooring system along a predetermined direction such that edges of each plank are arranged adjacent to the edges of other planks along the predetermined direction (e.g., an edge of plank 150A is adjacent an edge of plank 150B, an edge of plank 150C is adjacent an edge of plank 150D, etc.). As mentioned above, a substantially continuous pattern may be formed across an individual plank 150 because the bulk pattern 154 is substantially aligned with the edge patterns 152.

In an embodiment of the invention, the predetermined direction in which the planks are arranged is based on the adjacent edge patterns 152 in the planks, such that only by arranging the planks in the predetermined direction will the pattern formed be continuous and natural-looking. In this embodiment, reversing a plank or flipping a plank over will result in a discontinuous pattern. However, it is understood that in another embodiment, the edge patterns along a portion of the perimeter may be selected such that reversing, flipping or otherwise rearranging planks does not disrupt the pattern, i.e. the pattern is continuous.

In another embodiment, the predetermined direction is based on the interlocking mechanism that joins adjacent planks, such that the planks will not fit together properly if they are arranged in a direction other than the predetermined direction. One example of such a interlocking mechanism is a glueless tongue and groove system, in which the tongue is formed along at least one edge of the plank and the groove formed along the opposite edge. In yet another embodiment, the predetermined direction is based on both the edge patterns 152 and the glueless locking mechanism.

According to the principles of the present invention, bulk patterns 154A-154F may or may not be the same. In one aspect of the present invention, each of the bulk patterns 154 within a flooring system may be unique. Further, according to the principles of the present invention, edge patterns of individual planks may be substantially identical. Therefore, edge patterns of adjacent planks in a flooring system, across which a substantially continuous pattern is formed along the predetermined direction, are also substantially identical. A substantially continuous pattern may be provided across plank 150A because bulk pattern 154A and edge patterns 152A are aligned with each other to produce a substantially continuous pattern. Substantially continuous patterns may be individually provided across planks 150B, 150C, etc., because their respective bulk patterns 154B, 154C, etc., and edge patterns 152B, 152C, etc. are similarly aligned with each other to produce a substantially continuous pattern.

Because the edge patterns of planks 150A-150F within the flooring system illustrated in FIG. 15B are identical, edge pattern 152A forms a substantially continuous pattern with edge pattern 152B, edge pattern 152C forms a substantially continuous pattern with edge pattern 152D, and so on. Accordingly, a substantially continuous pattern may be formed across planks 150A and 150B, across planks 150C and 150D, and so on. The boundary or joint between the edge pattern 152A and the edge pattern 152B is substantially not visible, or the appearance of the presence of the boundary or joint is minimized. Similarly, the boundary or joint between the edge pattern 152C and the edge pattern 152D is substantially not visible, or the appearance of the presence of the boundary or joint is minimized. The boundary or joint between the edge pattern 152E and the edge pattern 152F is substantially not visible, or the appearance of the presence of the boundary or joint is minimized.

In one embodiment of the present invention, in which the edge patterns 152 are all substantially identical, any of the planks 150A-150F may replace any other plank within the flooring system while still maintaining the presence of a substantially continuous pattern across planks arranged adjacent each other along the predetermined direction. This is because all bulk patterns of a plank are substantially aligned with their respective edge patterns to form substantially continuous patterns within a plank and because all edge patterns of planks adjacent each other within a flooring system are identical, forming form substantially continuous patterns across planks adjacent each other along the predetermined direction.

In another embodiment, planks may have adjacent right and left edge patterns 152 substantially identical, while opposite left and right edge patterns 152 are not.

For example, in FIG. 15C, the unitary sub-panel 132 of plank 150 may have a pattern provided by a bulk pattern 154G, partial sub-panel 134 may have a pattern provided by bulk pattern 154I and edge pattern 152, and partial sub-panel 136 may have a pattern provided by bulk pattern 154H and edge pattern 152, wherein the bulk patterns 154G-154I may or may not be the same. As mentioned above, however, the edge pattern 152, present at the perimeter of the partial sub-panel portions 134 and 136 of the plank 150 and extending along a portion of the edges of the plank 150, are identical to each other. Accordingly, in view of FIG. 13A, when, for example, planks 130A and 130B are arranged adjacent each other along a predetermined direction, edge patterns 152 of complementary partial sub-panels 134A and 136B are substantially identical to each other and a substantially continuous pattern may be formed across adjacent planks, wherein the bulk patterns of the complementary partial-sub panels become a part of a substantially continuous pattern, appearing, visually and/or texturally as a unitary sub-panel.

Furthermore, referring now to FIGS. 15C and 15D, flooring systems incorporating planks such as those illustrated in FIGS. 13A-14C may be provided with substantially continuous patterns across planks adjacent each other along predetermined directions by applying the techniques described above with reference to FIGS. 15A and 15B. FIG. 15D shows the planks having a wood grain pattern in the arrangement shown in FIG. 15B. Because the edge pattern 152A is substantially identical to the adjacent edge pattern 152B, planks 150A and 150B have the appearance of a substantially continuous wood grain pattern running uninterrupted across the boundary or joint between edge pattern 152A and edge pattern 152B of the adjacent plank.

In addition, because the edge patterns 152A and 152B do not run along the entire length of the boundary or joint between planks 150A and 150B, but only along the portion corresponding to the height of the partial board on the bottom half of the planks, the pattern is not continuous across that portion of the boundary between planks 150A and 150B corresponding to the height of the complete boards on the top half of the planks.

As mentioned above, within the flooring system incorporating the planks illustrated in FIGS. 13A-14C and 15C, the bulk patterns within the sub-panels of the planks may or may not be the same. In one aspect of the present invention, each of the bulk patterns within the flooring system may be unique.

FIG. 15E shows an embodiment of the invention in which the edge patterns of the planks are identical (or substantially identical) in every plank. Specifically, FIG. 15E shows four planks, 150A, 150B, 150C, and 150D arranged such that plank 150A is adjacent the left edge of plank 150B and adjacent to a top edge of plank 150C. Plank 150D is adjacent to the right edge of plank 150C and adjacent to the bottom edge of 150B.

In this embodiment, the decor paper of each plank has a wood design. However, it is understood that other natural looking designs other than wood are contemplated by this invention as well. The wood design in plank 150A includes, for example, a complete board or strip 155A on a top half of the board, a short incomplete board 151A and a long incomplete board 153A. Each of the boards has a wood grain pattern. In addition, the short and long incomplete boards 151A and 153A have an edge pattern 152 running along a portion of the perimeter of the plank corresponding to the width of the incomplete boards 151A and 153A, and may extend a small distance (such as one centimeter, for example) into the interior of the boards. The edge patterns 152 of incomplete boards 151A and 153A are identical. The edge patterns 152 may also not extend into the interior of the boards.

Similarly, planks 150B, 150C, and 150D have complete boards 155B, 155C, and 155D, respectively, running the length of the plank, and short boards 151B, 151C, and 151D which are adjacent to long boards 153B, 153C, and 153D, respectively. Each of the short and long boards may have an identical edge pattern 152 along a portion of the perimeter of the plank corresponding to the width of the short and long boards.

All short boards 151A-D, long boards 153 A-D, and complete boards 155A-D have wood grain patterns that are different from each other or some identical to each other. Only the edge patterns 152 in the incomplete boards are identical in this particular example. Furthermore, the edge pattern and interior wood grain pattern of each incomplete board form a continuous pattern. In other words, there is a continuous overall wood grain pattern on each of the short boards and long boards that are all different from one another, despite the fact that the edge patterns 152 are the same.

When planks 150A and 150B are placed adjacent to one another as shown in FIG. 15E, complete boards 155A and 155B will be adjacent to each other, and long board 153A and short board 151B will be adjacent. Complete boards 155A and 155B appear as separate boards and the wood grain pattern is discontinuous across them, because the adjacent edges of the complete boards are different. But because the edge patterns 152 in long board 153A and short board 151B are the same, the unique wood grain patterns of 153A and 151B appear to form a single continuous board with a unique wood grain pattern running across the planks 150A and 150B. Furthermore, the appearance of a complete and continuous board with a unique wood grain pattern running in boards 153A and 151B across the planks minimizes the visibility or appearance of the joint or boundary between the planks. Similarly, the wood grain pattern across boards 153C and 151D is continuous.

In a further embodiment, the planks 150A, 150B, 150C, and 150D may have a surface texture that is embossed in registration with the wood design on the decor paper. Because edge patterns 152 are part of that wood design and may be the same or substantially identical in every plank, the embossed surface texture will appear to be continuous along the incomplete boards of adjacent planks in the manner discussed above. In still another embodiment, the embossed in registration surface texture may include bevels to imitate seams between boards, such that in plank 150A, for example, the complete board 155A would have a bevel running along its perimeter, including the boundary between board 155A and incomplete boards 151A and 153A. The incomplete boards 151A and 153A would have a bevel where they are adjacent, but the incomplete boards would not have a bevel along the portion of the perimeter of the plank 150A where the edge patterns 152 are located. In this way, a continuous wood grain pattern and corresponding embossed in registration surface texture can run continuously across planks 150A and 150B uninterrupted by a bevel. This would further reduce the appearance of the boundary between planks.

By having all edge patterns 152 to be identical, the present invention allows any planks to be fit together in the predetermined direction in which a long board 153 is adjacent a short board 151 of another plank, because the edge patterns 152 will always line up to form the appearance of a continuous wood grain pattern running across the adjacent long and short boards of the two planks. For example, if the positions of planks 150A and 150B were reversed (such that plank 150B was adjacent a top edge of plank 150C), the edge pattern 152 of long board 153B would match or be aligned with the edge pattern of short board 151A, forming a continuous wood grain pattern in the boards 153B and 151A across planks 150B and 150A.

The present invention reduces the complexity involved in installing a laminated floor, because it does not matter which planks are placed adjacent to one another in the predetermined direction. The patterns will be aligned. In a further embodiment, the planks 150 are provided with a glueless interlocking tongue and groove system in which the tongue is formed on two adjacent perimeter edges of the plank and the groove is formed in the opposite two adjacent perimeter edges so that the planks can only be fit together in the direction that will align long boards 153 with short boards 151, for example, where edge patterns 152 meet.

In the exemplary embodiment discussed above, the decorative motifs and design pattern elements such as wood strips run across separate adjacent planks. However, the wood strip motif has a length equal to that of the length of the plank, in order to allow for the interchangeability of planks, ensuring an easy installation.

Now making reference to FIG. 16, FIG. 16 illustrates a floor 501 having a floor pattern 500 formed by patterns 500 a through 500 d in accordance with an embodiment of the present invention. A plurality of flooring units having a decorative motif 512 disposed thereon define the floor 501. In particular, the plurality of flooring units includes flooring units 504, 506, 508 and 510, as more clearly shown with reference to FIGS. 17A through 17D.

FIG. 17A is an embodiment of the present invention illustrating the flooring unit 504 which includes subunits 504 a through 504 d. The subunits 504 a through 504 d form the flooring unit 504 such that a plank is formed. In the embodiment shown in FIG. 17A, the subunit 504 c has the decorative motif 512. It should be noted that in an alternative embodiment of the present invention, the subunit 504 b may include the decorative motif 512 instead of the subunit 504 c.

FIG. 17B illustrates the flooring unit 506 in accordance with an embodiment of the present invention. The flooring unit 506 includes subunits 506 a through 506 d. In this embodiment, the subunits 506 a through 506 d do not include a decorative motif, as discussed with reference to FIG. 17A and the flooring unit 504.

FIG. 17C is an embodiment of the present invention showing the flooring unit 508. The flooring unit 508 has subunits 508 a through 508 d. Here, the subunit 508 a has the decorative motif 512. Nonetheless, in accordance with embodiments of the present invention, the subunit 508 d may include the decorative motif 512 instead of the subunit 508 a.

FIG. 17D illustrates the flooring unit 510 in accordance with an embodiment of the present invention. The flooring unit 510 includes subunits 510 a through 510 d each having the decorative motif 512. In accordance with an embodiment of the present invention, the flooring unit 510, along with the flooring units 504, 506 and 508, includes ceramic tiles. In addition, the flooring units 504, 506, 508 and 510 may be any material used in flooring applications, such as wood, cork, marble or the like. It should be noted that the flooring units 504, 506, 508 and 510 have been described as having four subunits (e.g., subunits 504 a through 504 d). However, the flooring units 504, 506, 508 and 510 may have any number of subunits in accordance with the present invention, as will be discussed further on.

Returning attention to FIG. 16 and the floor pattern 500 shown therein, the flooring units 504, 506, 508 and 510 are aligned with respect to one another such that the decorative motifs 512 form the floor pattern 500. As previously mentioned, each of the flooring units 504, 506, 508 and 510 comprise four subunits. In this embodiment, the flooring units 504, 506, 508 and 510 are aligned such that the decorative motifs 512 disposed on the flooring units 504, 508 and 510 align with one another.

In order to form the pattern 500 a of the floor pattern 500, the subunit 504 c of the flooring unit 504 aligns with the subunit 508 a of the flooring unit 508 along an X-axis of the floor 501. More specifically, in order to form the pattern 500 a, the subunits 504 c of the flooring unit 504 align with the subunits 508 a of the flooring unit 508 to form the pattern 500 a. Likewise, both the subunit 508 a and the subunit 504 c align with the subunit 510 a of the flooring unit 510 thereby forming the pattern 500 a. It should be noted that the pattern 500 c is formed in a manner similar to the pattern 500 a, in accordance with an embodiment of the present invention.

In the embodiment shown with reference to FIG. 16, the subunit 510 d aligns with the subunit 510 a of a second flooring unit 510 along a Y axis of the floor pattern 500 such that decorative motifs 512 disposed on the first and second flooring unit 510 align along the Y axis. Additionally, in this embodiment, a subunit 508 a of a second flooring unit 508 aligns with the subunit 510 d of the second flooring unit 510 thereby forming the pattern 500 b as shown. It should be noted that in this embodiment, the pattern 500 d is formed in a manner similar to that described with reference to the pattern 500 b. In addition, the flooring units 506 are disposed within the floor pattern 500 such that the subunit 506 a is adjacent the subunit 504 d of the flooring unit 504 that forms the pattern 500 a.

As may be seen with reference to FIG. 16, an endmost subunit (e.g., the subunit 508 a or 508 d) of the flooring unit 508 aligns with a subunit adjacent an endmost subunit (e.g., the subunit 506 a or 506 d) of the flooring unit 506. Furthermore, in the embodiment shown in FIG. 16, the flooring units 504, 506, 508 and 510 have four subunits. Nonetheless, the flooring units 504, 506, 508 and 510 may have any number of subunits. For example, flooring units may have six subunits, as shown in FIGS. 19A through 19D.

FIG. 19A illustrates a flooring unit 514 having subunits 514 a through 514 f in accordance with an embodiment of the present invention. The flooring unit 514 also includes the decorative motif 512 on the subunit 514 e. FIG. 19B is an embodiment of the present invention showing a flooring unit 516. The flooring unit 516 has subunits 516 a through 516 f. FIG. 19C shows a flooring unit 518 having subunits 518 a through 518 f. In addition, the flooring unit 518 has the decorative motif 512 disposed on the subunit 518 a. Flooring unit 520, shown in FIG. 19D, includes subunits 520 a through 520 f each having the decorative motif 512 disposed thereon. The flooring units 514, 516, 518 and 520 may be used to form a floor pattern 522 for the floor 500 as shown in FIG. 18.

FIG. 18 illustrates an embodiment of the present invention where the flooring units 514, 516, 518 and 520 form a pattern 522 including patterns 522 a through 522 d. In this embodiment, subunits 514 e, 518 a and 520 a form the pattern 522 a as shown. Likewise, pattern 522 c is formed in a manner similar to that used for the pattern 522 a. In addition, subunits 520 a through 520 f and subunits 518 a form the patterns 522 b and 522 d as illustrated.

As may be seen with reference to FIGS. 16 and 18, the patterns of the floor 501 are formed with decorative motifs disposed on the following: an edge most subunit of a flooring member, a subunit immediately adjacent an edge most subunit, and a flooring unit having decorative motifs disposed on all subunits of the flooring unit. Additionally, a flooring unit which does not include decorative motifs is also used in forming the patterns of the floor 501. Therefore, flooring units having at least three subunits may be used to form patterns on a floor in accordance with the present invention.

In addition, in an embodiment of the present invention where a flooring unit includes four subunits, three flooring units may be used as illustrated in FIG. 20. In this embodiment, one flooring unit includes a decorative motif on all of the subunits, such as the flooring unit 510. A second flooring unit has a decorative motif on any one of the subunits, such as either the flooring unit 504 or 508. The subunits of the third flooring unit are all devoid of the decorative motif similar to the flooring unit 506. In FIG. 20, the subunits 508 a and 510 a form patterns 513 a and 513 c of pattern 513. In addition, the flooring unit 510 and the subunits 508 a from patterns 513 b and 513 d of the pattern 513.

In a further embodiment, where a flooring unit includes five subunits, four flooring units 524, 526, 528 and 530 may be used as more clearly illustrated in FIG. 21 to form the pattern 531 having patterns 531 a through 531 d. Making reference to FIGS. 22A through 22D, the flooring units 524, 526, 528 and 530 include five subunits. The flooring unit 524 includes subunits 524 a through 524 e. The flooring unit 526 has subunits 526 a through 526 e where all the subunits include the decorative motif 512. The flooring unit 528 has the subunits 528 a through 528 e. Here, the subunit 528 d has the decorative motif 512. The flooring unit 530 includes subunits 530 a through 530 e where the subunit 530 c has the decorative motif 512.

Returning attention to FIG. 21, the subunits 526 a and 528 d form the pattern 531 a. The flooring unit 526 also forms the patterns 531 b and 531 d. Furthermore, the subunits 526 e and 530 c form the pattern 531 c such that the pattern 531 is formed on the floor 501.

It should be noted that in accordance with embodiments of the present invention, many types of patterns for the floor 501, such as the patterns 500 and 522, may be formed using either of the flooring units 504, 506, 508 and 510 or the flooring units 514, 516, 518 and 520.

Furthermore, in one embodiment of the present invention, the subunits may be staggered from one another, as more clearly shown in FIG. 16 where the subunit 500 a aligns with the subunit 504 c. In embodiments where the subunits are offset from one another, four flooring units, (e.g., the flooring units 504, 506, 508 and 510) may be used irrespective of the number of subunits.

FIG. 23 illustrates a further embodiment of the present invention. FIG. 23 illustrates a flooring system having four (prior to milling the tongue and groove edges of each plank) distinctly patterned planks 1000, 1002, 1004 and 1006, each divisible into four equal subunits a, b, c, and d). The embodiment in FIG. 23 includes a decorative motif that has a width less than the width of a subunit.

As illustrated in FIG. 23, plank 1000 does not include the decorative motif FIG. 1002 includes the decorative motif on only a portion of one of the four subunits of the plank 1002. In this example, the decorative motif has a height (the direction parallel to the length of the plank) substantially equal to half of the height of a subunit. Plank 1004 includes the decorative motif on a different subunit of the plank. In other words, the subunit of plank 1004 that includes the decorative motif is different from the subunit of plank 1002 that includes the decorative motif.

Finally, plank 1006 includes the decorative motif running the entire length of the plank but only in a portion of each of the subunits. For example, the decorative motif may have a width (the direction parallel to the short side of the plank) equal to half the width of the plank, but runs the entire length of the plank. In other embodiments or other aspects of this embodiment the decorative motif may have a different width, that width being less than the total width of a plank.

After the planks are milled with the profiled edges, at least seven different planks are required in the flooring system according to this embodiment. However, if the planks have a joint system in which the joining mechanism or joint profile on opposite edges of the planks are the same, then only the four planks discussed above are required for this flooring system.

Because the decorative motif is on only a portion of each subunit, if the subunits are placed adjacent to one another such that entire subunits are adjacent to an entire subunit, then, as illustrated in FIG. 24, the flooring system will include a plank 1000 which is the same as that illustrated in FIG. 23, a plank 1002 which is similar to that illustrated in FIG. 23, and a plank 1004 which is similar to that illustrated in FIG. 23. However, there are also additional planks, including plank 1003, which is the same as plank 1004 rotated 180°. Plank 1003 may be placed adjacent to planks 1006 and 1002 such that the decorative motif on the adjacent planks are aligned. There is also a plank 1005, similar to the plank 1002 rotated 180°, that may be placed adjacent to plank 1003 such that the decorative motif lines up across adjacent subunits of the planks. Furthermore, the flooring system includes plank 1007 which is similar to plank 1006 rotated 180°. Thus the flooring system having planks 1000, 1002, 1003, 1004, 1005, 1006 and 1007 is able to create a flooring pattern illustrated in FIG. 24 which has a height equal to the length of two planks (or eight subunits in which each plank had a total of four subunits and a width of nine planks, however, because the decorative motif is only on a portion of the width of the planks 1006 and 1007, the actual width of the decorative motif is eight planks wide, although it requires a total of nine planks to create the pattern.

FIG. 24 illustrates a flooring pattern created using the seven planks of this flooring system in which the decorative motifs occupy only on a portion of a subunit of the plank rather than the entirety of the subunit as was illustrated in embodiments discussed earlier. Because the decorative motif is offset within each subunit in this fashion, this flooring system is able to disguise the physical joints between adjacent planks using this flooring system. More specifically, in FIG. 24, plank 1003 is placed adjacent to plank 1006 such that the second subunit of plank 1003, identified as subunit 1003 b, is adjacent to the first subunit 1006 a of plank 1006. Similarly, subunit 1005 d is adjacent to subunit 1003 b of plank 1003. In this way, planks 1003 and 1005 are offset from each other by a distance of two subunits, or half of the total length of the plank, whereas, plank 1003 is offset from plank 1006 by a distance of only one subunit or a quarter of the length of the plank. This difference in offsets between planks 1006 and 1003 and 1003 and 1005 further aids in disguising the physical joints between adjacent planks.

The arrangement of planks 1003 and 1005 discussed above may be repeated to create a flooring pattern having a variable width, as illustrated in FIGS. 24 through 26. The width of the overall pattern in this embodiment is equal to the total number of planks 1003 and 1005 placed adjacent to one another plus one plank width which is the total decorative motif width from the portion of the decorative motif on plank 1006 plus the portion of the decorative motif on plank 1007. This is the case because, in this example, the width of the decorative motif equals one half the width of a plank. Thus, in FIG. 24 there are seven planks 1003 and 1005 (four of plank 1003 and three of plank 1005) between planks 1006 and 1007 to create a decorative motif in a flooring pattern having a width equal to eight plank widths even though the flooring pattern itself is created with nine physical flooring planks.

Furthermore, as illustrated in FIG. 25, the height of the flooring pattern may be extended to any multiple of plank lengths simply by running additional planks 1006 adjacent to one another in the vertical direction—the vertical direction being parallel to the length of the plank. Therefore, by adding additional planks 1006 adjacent to one another on one side and additional planks 1007 adjacent to one another on the opposite side, the height of the overall flooring pattern may be extended. This is further illustrated in FIG. 25 which has a flooring pattern with a height equal to three plank lengths created by three planks 1006 adjacent to one another on one side and three planks 1007 adjacent to one another on the other side. The flooring pattern has a width equal to the width of twelve flooring planks even though thirteen planks are required to complete the flooring pattern in the width direction.

Furthermore, and as illustrated in FIG. 26, with the flooring system of the embodiment currently discussed, the smallest flooring pattern that may be created is a flooring pattern having a height equal to the length of one plank and a width equal to the width of four planks and requires five planks placed adjacent to one another in the width direction, specifically planks 1006, 1005, 1003, 1005 and 1007 to create this flooring pattern.

It is understood that the various additional embodiments in which the decorative motif has a width less than the total width of a plank and not equal to half the width of the plank, and in which the height of the decorative motif is some height other than the total height of the subunit and different from half the height of the subunit. Furthermore, it is understood that depending on the width of the flooring motif of the decorative motif greater or fewer planks may be required in the flooring system to enable the creation of floors having flooring patterns of various widths and heights. 

1. A system of forming a decorative pattern, the system comprising: a first unit, the first unit comprising: a first plurality of subunits having a pattern, wherein a subunit of the first plurality of subunits includes a decorative motif substantially different from the unit pattern; and a second unit adjacent the first unit, the second unit comprising: a second plurality of subunits having the pattern, wherein a subunit of the second plurality of subunits includes the decorative motif where the first subunit and the second subunit align with one another such that the decorative motifs of the first subunit and the second subunit align with one another thereby forming the decorative pattern.
 2. The system as recited in claim 1, the system further comprising: a third unit, the third unit comprising: a third plurality of subunits having the pattern, wherein a subunit of the third plurality of subunits includes the decorative motif such that the decorative motif of the third subunit forms the decorative pattern with the decorative motif of both the first subunit and the second subunit.
 3. The system as recited in claim 2, the system further comprising: a fourth unit, the fourth unit having at least four subunits.
 4. The system as recited in claim 3, wherein the subunit of the first unit having the decorative motif is adjacent the subunit of the second unit having the decorative motif.
 5. The system as recited in claim 4, wherein an edge unit of the first unit has the decorative motif.
 6. The system as recited in claim 4, wherein a subunit adjacent an edge unit of the second unit has the decorative motif.
 7. The system as recited in claim 1, wherein the first unit includes at least four subunits.
 8. The system as recited in claim 1, wherein the second unit includes at least four subunits.
 9. The system as recited in claim 1, wherein the first unit and the second unit are laminate flooring planks having wood grain patterns.
 10. The system as recited in claim 1, wherein the subunits comprise an embossed surface texture in registration with the decorative motif.
 11. The system as recited in claim 1, the first unit comprising: a tongue extending from a perimeter of one edge of the first unit; and a groove running along a perimeter of an opposite edge of the first unit.
 12. The system as recited in claim 11, the second unit comprising: a tongue extending from a perimeter of one edge of the second unit; and a groove running along a perimeter of an opposite edge of the second unit where any of the grooves are capable of receiving any of the tongues.
 13. The system as recited in claim 9, wherein the pattern comprises an embossed surface texture.
 14. The system as recited in claim 1, wherein the first and second units are laminate flooring planks having a ceramic tile surface pattern.
 15. A method of forming a decorative pattern, the method comprising: arranging a first unit, the first unit having a plurality of subunits with a pattern where a first subunit of the first plurality of subunits has a decorative motif with a pattern different from the subunit pattern; and placing a second unit adjacent the first unit, the second unit having a plurality of subunits with the subunit pattern where one subunit of the second plurality of subunits has the decorative motif where the first subunit having the decorative motif is adjacent the second subunit having the decorative motif thereby forming the decorative pattern.
 16. The method as recited in claim 15, the method further comprising: arranging a third unit adjacent the first unit or the second unit, the third unit having a plurality of subunits where one subunit of the third plurality of subunits has the decorative motif where the third subunit having the decorative motif is adjacent one of the first subunits having the decorative motif and the second subunit having the decorative motif.
 17. The method as recited an claim 15, wherein the first unit has a tongue extending from a perimeter of a first edge and a groove at a perimeter of a second edge opposite the first edge.
 18. The method as recited in claim 17, wherein the second unit has a tongue extending from a perimeter of a first edge and a groove at a perimeter of a second edge opposite the first edge.
 19. The method as recited in claim 18, further comprising: interlocking the second unit tongue with the first unit groove.
 20. The method as recited in claim 15, wherein the first unit and the second unit are laminate flooring planks having wood flooring planks.
 21. The method as recited in claim 15, wherein the subunits comprise an embossed surface texture in registration with the decorative motif.
 22. The method as recited in claim 20, wherein the pattern comprises an embossed surface texture.
 23. The method as recited in claim 15, wherein the first and second units are laminate flooring planks having ceramic tile patterns.
 24. The method as recited in claim 15, wherein both the first unit and the second unit include at least four subunits.
 25. A system for forming a decorative pattern, the system comprising: a first unit having a plurality of subunits where the first plurality of subunits have a pattern disposed thereon, one subunit of the first plurality of subunits having a decorative motif where the decorative motif is substantially different from the subunit pattern; and a second unit having a plurality of subunits where the second plurality of subunits have the subunit pattern and one subunit of the second plurality of subunits has the decorative motif where the decorative motifs of the first subunit and the second subunit align with each other when the first unit is set offset relative to the second unit wherein the aligned decorative motifs form the decorative pattern.
 26. The system as recited in claim 25, the system further comprising: a third unit having at least four subunits, where one of the one subunits has the decorative motif such that when the third unit is set offset relative to both the first and second units, the decorative motif of the third subunit aligns with the decorative motifs on the first subunit and the second subunit.
 27. The system as recited in claim 25, the system further comprising: a fourth unit having at least four subunits.
 28. The system as recited in claim 25, wherein both the first unit and the second unit have at least four subunits. 